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Duct board is okay for use in our area, and I'm familiar with the flex duct. But, am concerned about the potential for mold growth with the fiberglass duct board...and the flex duct won't work for the main plenum.

why dont you want metal ducts, insulate them and you are good to go.. sorry to say in Az we use flex-duct it does the job, but I prefer sheet metal it lasts longer and doesnt collapse on you. flex-duct is not up to code in all areas so check your local codes first... good luck...